Rev.

PO No :
4501314521 0
ZIG-ZAG TRANSFORMER
APPLICATION IN 20 KV Document No :
-
SYSTEM
19 Pages (with cover)

Project :

ZIG-ZAG TRANSFORMER

Owner :

PT HM SAMPOERNA TBK

Location :

PASURUAN PLANT

0 Issued for Approval 05/06/2017 IR DG GK

Rev. Description Date Prepared Reviewed Approved

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TABLE OF CONTENTS

1. Purpose ............................................................................................................ 2

2. References ....................................................................................................... 2

3. Plant Operation Scheme .................................................................................. 2

4. Design Objective .............................................................................................. 3

5. Equipment Sizing ............................................................................................. 5

6. Protection Setting and Coordination Study ................................................... 8

7. Conclusion and Recommendation ................................................................17

PT GANSAR JAYA
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1. Purpose

The purpose of this document is to describe Zig-Zag Transformer Application in 20 kV

System for HMS Sukorejo Plant located on the Sukorejo – Jawa Timur. Philosophy of
operation, equipment sizing and protection scheme are also presented here.

2. References

[1] IEEE Std C62.92.4-1991 Guide for the Application of Neutral Grounding in Electrical
Utility Systems – Part 4 Distribution
[2] IEEE Std 142-2007 IEEE Recommended Practice for Grounding of Industrial and
Commercial Power Systems
[3] IEEE Std 32-1972 IEEE Standard Requirements, Terminology and Test Procedures
for Neutral Grounding Devices
[4] IEEE Std 242-2001 IEEE Recommended Practice for Protection and Coordination of
Industrial and Commercial Power Systems
[5] National Electrical Code, National Fire Protection Association (NFPA) 70, 2005
Edition
[6] Arun Phadke, Power System Protection, The Electric Power Engineering Handbook,
CRC Press LLC, 2001

3. Plant Operation Scheme

20 kV electrical plant of HMS Sukorejo is based on the use of Gas Engine Generator
(GEG) and National Utility (PLN) scheme. Power generated from two unit of gas engine
generators are delivered to the 20 kV system switchgear through each step up
transformers 3000 kVA, 0.4/20 kV, Dyn5.

Under normal conditions, two units of GEG will operate in parallel with each other as well
as with the 20 kV PLN Distribution Grid to supply factory load of HMS Sukorejo. And 20
kV PLN Distribution Grid is delivered from step down power transformer 150/20 kV in HV
Substation with wye connection at low side terminal voltage.

In the event of 20 kV PLN Distribution Grid is disconnected from 20 kV electrical plant due
to some reasons, GEG will operate in island mode and Diesel Engine Generator (DEG)
will start automatically or manually to support GEG to supply factory load, through step up
transformer 2000 kVA, 0.4/20 kV, Dyn5. In this condition, 20 kV system will have
ungrounded or isolated system. See figure 1 for simplified single line diagram of HMS
Sukorejo Plant.

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If a single line-to-ground fault occurs on an ungrounded or isolated system, no return path

exists for the fault current, thus no current flows. The system will continue to operate but
the other two un-faulted phases will rise in voltage by the square root of 3, resulting in
overstressing of the transformer insulation and other associated equipments on the
system by 173%. A grounding transformer provides a ground path to prevent such
condition.

The best way to obtain the system neutral for grounding purposes in three phases
systems is to use source transformers or generators with wye-connected windings and
the neutral is readily available. When the system neutral may not available, grounding
transformer may be used to obtain the neutral as shown in figure 1.
PLN GRID
150 / 20 kV
wye connection
4 units of 2 units of
G Diesel Engine Generator G Gas Engine Generator
2000 kVA, 0.4 kV, 2000 kW, 0.4 kV,
50 Hz, PF 0.8 50 Hz, PF 0.8

CLOSE CLOSE

4 units of 2 units of
Power Transformer Power Transformer
2000 kVA, 0.4 / 20 kV, 3000 kVA, 0.4 / 20 kV,
Dyn 5 Dyn 5

CLOSE CLOSE OPEN

20 kV Switchgear

CLOSE CLOSE CLOSE

Transformer Transformer Zig-Zag Transformer

20 / 0.4 kV, 20 / 0.4 kV,
Dyn 5 Dyn 5

Neutral Grounding
R
Resistor (NGR)
CLOSE CLOSE

Factory Load Factory Load

Figure 1 – simplified single line diagram with Zig-Zag transformer

for 20 kV system neutral in island operation

4. Design Objective

Grounding transformer provide artificial neutral and is used as following

to ground an otherwise un-grounding system
to provide a relatively low impedance path to ground
to limit the magnitude of transient over voltages when re-striking ground faults occur
to limit the current during a line to ground fault and possible additional resistors for
permitting selective protection
to permit the connection of phase to neutral loads when desired

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Grounding transformer may be conected in any manners as interconnected wye (Zig-Zag)

or wye delta.

Figure 2 – Zig-Zag transformer arrangement

Zig-Zag transformer is three-phases with no secondary winding. Each phases has two
identical windings, which are wound in opposite directions to give the high impedance to
normal phase currents. The neutral point is then connected either directly or through a
neutral grounding resistor (NGR) to ground.

When a ground fault occurs, ground fault current flows through the fault, back through
ground and NGR to Zig-Zag transformer where the current is divided equally in each leg
of Zig-Zag transformer. Since these three currents are all equal in phase with each other
(zero sequence) and because of special Zig-Zag winding connections, the currrents will
flow through very low impedance. This allows the ground fault current to flow back into the
system. The ground fault current is only limited by the resistance of the ground fault,
Neutral Grounding Resistor (NGR) and the small reactance of Zig-Zag transformer.

Figure 3 – ground fault current occurs on any phase of the system

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5. Equipment Sizing

Zig-Zag transformer is normally designed for short time rating of 10 seconds to one
minute, since the transformer is only required to carry ground fault current until the circuit
breakers clear the fault and de-energize the faulted circuit. Consequently, the transformer
is much smaller in size than an ordinary continuously rated transformer with the same
rating.

Zig-Zag transformer must be sized to carry the rated continuous primary phase current
without exceeding its temperature limit. The transformer constructed in accordance with
IEEE Std 32 will have a continuous rating of 3% for a 10 s rated unit. If higher values of
continuous current are required, the size of the transformer may increase. One minute
rated unit would have a continuous current rating of 7%.

The fault duration is a critical parameter. Where protection schemes use Zig-Zag
transformer for tripping functions, a relatively short time duration is specified (5 - 10
seconds). On the other hand, a continuous or extended neutral fault current duration
would be required when the transformer is used in a ground fault alarm scheme.

5.1 NGR Sizing

By limiting ground fault current of the system to 100 Amperes using NGR and
system parameter below,

VL-L = 20 kV
VL-G = 11.5 kV
IG = 100 Amp = 0.1 kAmp

Rated voltage of the NGR should be equal to the line to ground voltage of the Zig-
Zag transformer. Current rating and duration should match the Zig-Zag transformer
rating.

Then, resistance value of NGR is

R NGR = VL-G / IG ......................................................................................(1)

= 11.5 / 0.1 Ohms
= 115 Ohms

Selected NGR is 11.5 kV rated voltage, 100 Amp, 10 seconds and 115 Ohms.

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5.2 Zig-Zag Transformer Sizing

In this section contain a series of calculation for Zig-Zag transformer using per-unit
quantities. System parameter that will be used in calculation as follow

VL-L = 20 kV (ungrounded system)

ISC = 25 kAmp (short circuit rating in 20 kV system)
IG = 100 Amp = 0.1 kAmp (limit of ground fault current)
MVA base = 100 MVA

MVA SC = √3 . VL-L . ISC .............................................................(2)

= √3 . 20 . 25
= 866.03 MVA

Z base = (1000) . (VL-L)2 / (kVA base) .....................................(3)

= (1000). (20)2 / (100 . 1000)
= 4.0 Ohms

I base = kVA base / (√3 . VL-L ) .................................................(4)

= (1000 . 100) / (√3 . 20 )
= 2886.75 Amp

Z pos seq = 100 / 866.03

= 0.115 pu

Z neg seq = 100 / 866.03

= 0.115 pu

IG = IG / I base .........................................................................(5)
= 100 / 2886.75
= 0.035 pu

I zero seq = IG / 3 .........................................................................(6)

= 0.035 / 3
= 0.012 pu

Z total = 1 / I zero seq .............................................................(7)

= 1 / 0.012
= 86.603 pu

Z total = Z pos seq + Z neg seq + Z zero seq .....................................(8)

Z zero seq = 86.603 – 0.115 – 0.115

= 86.37 pu

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Z zero seq = Z zero seq (pu) . Z base .................................................(9)

= 86.37 . 4.0
= 345.49 Ohms / phase

Since ground fault current is limited by NGR, impedance of zero sequence of Zig-
Zag transformer is very low compared with the resistance value of NGR. Then,

Z zero seq = 3 . R NGR .......................................................................(10)

R NGR = 345.49 / 3
= 115.16 Ohms

For kVA rating of Zig-Zag transformer, since both windings are active in the primary circuit,
the short time rating can be calculated with the following formula

Figure 4 – voltage and ground fault current distributions on each windings

kVA short time = IG . VL-L / 3 ...........................................................(11)

= 100 . 20 / 3
= 666.67 kVA

IEEE Std 32 requires continuous rating of 3% for 10 seconds rated unit. Therefore,
Zig-Zag transformer should be rated

kVA continuous = k. IG . VL-L / 3 ...........................................................(12)

and k is constant value for continuous rating

kVA continuous = 3% . 100 . 20 / 3

= 22 Kva

According to the result of this study, it is further confirmed that selected rating of Zig-
Zag transformer should be minimum 666.67 kVA short time rating, 100 Amps, 10
seconds. And rating of Zig-Zag transformer should also be designed continuous
unbalanced load of 22 kVA with 3 Amps rated.

PT GANSAR JAYA
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6. Protection Setting and Coordination Study

The objectives of protection setting and coordination study are to limit the extent and
duration of service interruption whenever equipment failure, human error or adverse
natural events occur on any portion of the system and minimize damage to the system
components involved in the failure. These devices are generally applied so that upon a
fault, only a minimum portion of the power system is interrupted.

The circumstances causing system malfunction are usually unpredictable, however,

sound design and preventive maintenance can reduce the likelihood of system problems.
The electrical system, therefore, should be designed and maintained to protect itself
automatically.

The common protection for Zig-Zag transformer is three overcurrent relays that are
connected to current transformers located on the primary phase side. These current
transformers must be connected in delta to filter out unwanted zero sequence current. An
overcurrent ground relay located in neutral side will provide ground protection for this
scheme. It should be coordinated with other ground relays on the system.

Low resistance grounding has the advantage of facilitating the immediate and selective
clearing of a grounded circuit. This requires that the minimum ground fault current be
large enough to positively actuate the applied ground fault relay. One method of detecting
the presence of a ground fault uses an overcurrent ground relay, 50/51G. Remember to
set the current rating high enough to be above the cable charging current and Zig-Zag
transformer magnetizing current.

The following criteria considered for protective setting and coordination study
All of the fault current should be detected and respective circuit has to be switched
off to isolate the fault from the system. Only faulty network or branch has to be
switched off.
All of the over-current conditions caused by normal operation of equipment (i.e
motor starting current, transformer inrush current, etc) shall not recognize as a fault
by protective equipment or causing any protective equipment work.
Minimum time clearance between equipment’s protective curve should be 200ms.

The concern for ground fault protection is based on four factors :

Majority of electric faults involve ground. Even faults that are initiated phase to
phase spread quickly to any adjacent metallic housing, conduit or tray that provides
a return path to the system grounding point. Ungrounded systems are also subject
to ground faults and require careful attention to ground detection and ground fault
protection.
Ground fault protective sensitivity can be relatively independent of continuous load
current values and, therefore, have lower pickup settings than phase protective
devices.

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Because ground fault currents are not transferred through system power
transformers that are connected delta-wye or delta-delta, ground fault protection for
each system voltage level is independent of the protection at other voltage levels.
This configuration permits much faster relaying than can be afforded by phase
protective devices that require coordination using pickup values and time delays that
extend from the load to the source generators and often result in considerable time
delay at some points in the system.
Arcing ground faults that are not promptly detected and cleared can be destructive.

6.1 External Ground Fault

For external ground fault, only zero phase sequence current flow through the
primary of the delta connected CTs. Therefore, current will flow only in the external
fault back up ground overcurrent relay, 50/51G, and its time delay should be long
enough to be selective with other relays that should operate for external fault.
33.3 A
Phase A

33.3 A
Phase B
Phase C

66.7 A
100 A 50/
51

50/
51

50/
51
600 / 5 600 / 5 600 / 5
5P20 5P20 5P20

33.3 A 33.3 A 33.3 A

100 A

100 Amps trip main incoming

R 10 sec Circuit Breaker
115 Ohms
50/51
100 / 5 G
10P20

Figure 5 – external ground fault at phase C and current distributions on each windings

Protection coordination is listed as following

1. During ground fault at location F1, relay 50/51G of Zig-Zag transformer feeder
will be tripped to all main incoming circuit breakers (all power supplies),
otherwise relay 50/51N (residual connection) of all main incoming circuit
breakers will be tripped after delay time of 200ms.
2. During ground fault at location F2, relay 50/51G of Zig-Zag transformer feeder
will be tripped to all main incoming circuit breakers (all power supplies),
otherwise relay 50/51N (residual connection) of all main incoming circuit
breakers will be tripped after delay time of 200ms.

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3. During ground fault at location F3, relay 50/51N (residual connection) of

outgoing distribution transformer feeder will be tripped its circuit breaker first,
otherwise 50/51G of Zig-Zag transformer feeder and relay 50/51N of all main
incoming circuit breakers will be tripped after delay time of 200ms and 400ms
respectively.

Figure 6 – external ground fault tripping scheme at various fault locations

6.1.1 Protection setting for outgoing feeder to Zig-Zag transformer

Relay type : SEPAM S80

Ground CT ratio : 100 / 5 Amp

Protection element characteristic is

50/51G (current measured)
0.01 to 15 In0
0.05 sec to 300 sec

Secondary value of ground fault current is

In0 sec = IG / Ground CT ratio ...............................................(13)
= 100 / (100 / 5)
= 5 Amp

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The protection is set as 80% of ground fault current to consider very low
impedance of zero sequence of Zig-Zag transformer. Consequently, current
pick up is

Iset = 80% . In0 sec

= 4.0 Amp

This protection element initiates trip when ground fault has been present for
the time of 0.5 seconds.

Therefore, proposed protection setting is

current setting (Iset) : 0.8 In0
time delay (td) : 0.5 sec
selected curve : definite time

6.1.2 Protection setting for incoming feeder from step up transformer 0.4 /
20 kV

Relay type : SEPAM 1000

Phase CT ratio : 100 / 5 Amp

Protection element characteristic is

50/51N (current calculated)
0.05 to 2 In
0.1 sec to 90 sec

Secondary value of ground fault current is

In sec = IN / Phase CT ratio ...............................................(14)
= 100 / (100 / 5)
= 5 Amp

IN is ground fault current sensed by phase CT that calculate summation in

residual connection. The value is equal to IG.

The protection should be set as same as Iset of outgoing feeder to Zig-Zag

transformer since the magnitude of ground fault current is also 100 Amp
primary or 5 Amp secondary, but delay time is set as 200ms.

Therefore, proposed protection setting is

current setting (Iset) : 0.8 In
time delay (td) : 0.7 sec
selected curve : definite time

Above setting should consider unbalance load. Ground fault protection

setting with residual connection CT (50/51N) therefore should be evaluated
during commissioning. Longer time delay more than 0.7 seconds should be
applied.

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6.1.3 Protection setting for outgoing feeder to distribution transformer 20 /

0.4 kV

Relay type : SEPAM S80

Phase CT ratio : 600 / 5 Amp

Protection element characteristic is

50/51N (current calculated)
0.01 to 15 In0
0.05 sec to 300 sec

Secondary value of ground fault current is

In0 sec = IN / Phase CT ratio
= 100 / (600 / 5)
= 0.83 Amp

Iset = 80% . In0 sec

= 0.67 Amp

Iset = 0.67 / 5
= 0.133 In0

This protection element initiates trip when ground fault has been present for
the time of 0.3 seconds.

Therefore, proposed protection setting is

current setting (Iset) : 0.133 In0
time delay (td) : 0.3 sec
selected curve : definite time

Above setting should also consider inrush current during distribution

transformer energizing that can cause nuisance trip due to 2nd harmonic
current and unbalance load. Ground fault protection setting with residual
connection CT (50/51N) therefore should be evaluated during
commissioning and re-coordinated with upstream feeder as well.

6.1.4 Protection Coordination Curve

Time Current Characteristic (TCC) curve defines the operating time of

protective device for various magnitudes of operating current. From sub
clause 6.1.1, 6.1.2 and 6.1.3 above, coordination curve can be plotted as
shown in Figure 7 and 8.

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Figure 7 – TCC curve at fault location F1 and F2

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Figure 8 – TCC curve at fault location F3 and coordinated to upstream feeder

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6.2 Internal Ground Fault

Other overcurrent protections, 50/51, will provide protection for short circuit on Zig-
Zag transformer side of the CTs. These relays may be sensitive and quite fast
because, except for magnetizing current and small current that may flow through the
relays because of CT error, current will flow only when short circuit requiring tripping
occure. The pick up of overcurrent relays should be set at 5 times of Zig-Zag
transformer’s continuous current rating.
66.7 A
Phase A

33.3 A
Phase B
Phase C
0.83 A sec 33.3 A
50/
51

50/
66.7 A 51

50/
51
600 / 5 600 / 5 600 / 5
5P20 5P20 5P20

100 A
33.3 A 33.3 A Trip Zig Zag transformer
Circuit Breaker
33.3 A

100 A

100 Amps
R 10 sec
115 Ohms
50/51
100 / 5 G
10P20

Figure 9 – internal ground fault at phase A and current distributions on each windings

During internal ground fault, relay 50/51 of Zig-Zag transformer feeder will be tripped
to its internal circuit breaker faster than relay 50/51G. It’s not required to coordinate
this protection with other overcurrent relays of downstream and upstream feeders.
Then, relay 50/51G is a back up of relay 50/51 in this purpose.

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Engine Generator
G 0.4 kV, 50 Hz, PF 0.8

Power Transformer
0.4 / 20 kV, Dyn 5

50/51
N

trip cmd

trip cmd
20 kV Switchgear

trip cmd 50/51

G

50/51

F4

Zig-Zag Transformer

Neutral Grounding R
Resistor (NGR)

Figure 10 – internal ground fault tripping scheme at location F4

After tripping its circuit breaker, 20 kV system will be ungrounded or isolated. Plant
operator should be aware with condition occured and shutting down the system if
necessary.

Protection setting of 50/51 will be

Relay type : SEPAM S80

Phase CT ratio : 600 / 5 Amp

Protection element characteristic is

50/51
0.05 to 24 In
0.05 sec to 300 sec

Secondary value of ground fault current that sensed by the overcurrent

relay is
In sec = IN / Phase CT ratio
= 100 / (600 / 5)
= 0.83 Amp

In prim = 3 Amp (continuous rating)

In sec = 3 . 5 / 600
= 0.025 Amp

Iset = 5 . In sec
= 0.125 Amp

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Iset = 0.125 / 5
= 0.025 In
≈ 0.05 In

This protection element initiates trip instantaneously when ground fault has
been present.

Therefore, proposed protection setting is

current setting (Iset) : 0.05 In
time delay (td) : 0.05 sec
selected curve : definite time

From above setting, it’s seen that overcurrent setting is very low since
current ratio of phase current transformer is too high. Selected CT ratio
should be same as maximum limited ground fault current or less is
recommended.

7. Conclusion and Recommendation

Grounding system has a fundamental role in the safety and reliability of the plant
operation. In order to obtain high levels of availability in operation, attention should be
given how to select type of grounding and its associated protection scheme. In the
present report, Zig-Zag transformer application including its philosophy of operation,
sizing and protection scheme have been presented.

The main conclusions of this work as follow :

Zig-Zag grounding transformer is selected base on short time and continuous rating.
For this plant purpose, the transformer rating is 666.67 kVA for short time and 22 kVA
for continuous rating.

Ground fault current is limited to 100 Amps by means of NGR. Therefore total
impedance of zero sequence of transformer depends on resistance of NGR. Selected
NGR is 100 Amp, 10 sec, 115 Ohms.

There will be different scheme of Zig-Zag transformer protection, evaluation of internal

ground fault is solely for transformer protection and external ground fault is required
for system protection. Time grading is essential for external protection.

During normal conditions, two units of GEG will operate in parallel with the 20 kV PLN
Distribution Grid. Since 20 kV PLN Distribution Grid is delivered from step down
power transformer 150/20 kV with wye connection in low side terminal voltage,
interlocking between incoming feeder from PLN Distribution Grid and outgoing feeder
to Zig-Zag transformer shall be provided. Both circuit breakers can’t be closed
together at the same time in order to avoid mis-operation of ground fault protection
relay. Zig-Zag transformer can be utilized only in island operation.

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Phase CTs laid inside outgoing feeder of Zig-Zag transformer should be connected in
delta to filter out zero sequence current. However, relay manufacture shall confirm
with delta CTs configuration.

Phase CTs with lower ratio is recommended for Zig-Zag transformer overcurrent
protection. Selected CTs is based on maximum limited ground fault current and Zig-
Zag transformer continuous rating.

PT GANSAR JAYA